System and method for manufacturing embroidered furniture

ABSTRACT

A system and method for manufacturing embroidered furniture. There is a network configured to provide communication throughout the system; a furniture database module coupled to the network and configured to provide furniture data including flattened surface data for an article of furniture; a logo database module coupled to the network and configured to provide logo data for logos owned by third parties and licensed under licensing rules; a design module coupled to the network and configured to selectably receive and integrate logo data and furniture data according to licensing rules in a perspective view, thereby forming embroidery data; an embroidery supplier module coupled to the network and configured to receive embroidery data for the purpose of creating an embroidered surface; and/or a furniture manufacturer module coupled to the network and configured to receive an embroidered surface for assembly.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to manufacturing systems and methods, specifically to a system and method for manufacturing embroidered furniture.

2. Description of the Related Art

In the field of embroidery, substantial progress has been made in automation and systemization. Initially a form of art, embroidery has expanded to become an industry of mass scale. The variety of articles that may be embroidered is tremendous and such articles are often embroidered with a logo of an entity, such as baseball caps having the Major League Baseball logo, or T-Shirts having the Nike “swoosh.”

The success of the logo, especially in the United States, stems partially from the ability of the entity to promote the logo as being a desired item for the consumer. As an example, some clothing manufacturers, such as Gap and Old Navy, prominently display logos on clothing as a primary adornment. Where before, clothing may have been purchased for its cut, color, and style; now purchase decisions are often made based on what logo adorns the article.

Accordingly, manufacturers have endeavored to be able to adorn articles of manufacture with designs, symbols, lettering, etc. in order to fulfill the wants and needs of businesses and consumers. The following references reflect advances made in this and similar areas. Each of the following references are incorporated by reference herein:

U.S. Pat. No. 6,813,535 B2 by Akira et al. discloses an embroidering device connected to a network and the network system thereof is disclosed, wherein an embroidering device is connected to a personal computer by means of wire or wireless while the personal computer is connected to a network including an internet and is connected to an optional server. An instruction is given from the embroidering device to the personal computer to connect the embroidering device to the network and thereby to the server. The personal computer seeks a required one of the information prepared by the server and downloads the sought information. For example, the personal computer obtains a list of embroidery pattern data. When the user selects optional one of the pattern data, the selected pattern data is downloaded from the server and transmitted to the embroidery.

US Patent/Application No. US 2003/0033207 A1 by Litke et al. discloses a method for soliciting orders for customized apparel. The apparel can be appendage apparel, such as footwear, gloves, or head gear, or non-appendage apparel such as jackets. There includes providing an order form accessible through at least one computer by one or more users. There further includes providing one or more possible design parameters, requesting the user to customize the apparel by entering at least one of the parameters on the order form. The user submits the order form through the computer and receives apparel according to the order form. The parameters may include size, material, model, style, color, material treatment, or personalization.

US Patent/Application No. US 2004/0181465 A1 by Kan discloses a method for on-line outsourcing of customized merchandise containing at least a personalized logo. An on-line remote customer personalizes preferred logo image and customizes preferred merchandise image by selecting image parts and part elements stored, respectively, in logo image and merchandise image databases. The server generates a customized merchandise image containing at least a personalized logo image after receiving the remote customer's indication of the location(s) and size(s) of the personalized logo image to be incorporated with the customized merchandise image. Outsourcing and customization order databases store, respectively, information of outsourcing invoice and customization order records. The server transmits the customized merchandise image containing at least a personalized logo and outsourcing invoice to a supplier to bind the production of the tangible, customized merchandise. The server also transmits the customized merchandise image containing at least a personalized logo and customization order to the remote customer to bind the customization.

Further references are included in the-table below: U.S. Pat. No. TITLE INVENTOR U.S. Pat. No. 2004/0181465 A1 Method for on-line outsourcing of customized Kan merchandise containing personalized logo U.S. Pat. No. 2003/0033207 A1 Computerized Article Customization System Litke et al and Method for use thereon U.S. Pat. No. 6,813,535 B2 Embroidering Device Connected to Network Akira et al. and the Network System thereof U.S. Pat. No. 6,502,006 B1 Method and System for Computer Aided Laufer et al Embroidery 6,871,605 B1 Computerized Stitching including Embroidery Zesch et al 6,983,192 B2 Computerized Stitching including Embroidery Block et al U.S. Pat. No. 2004/0172149 A1 Order Based Production System Eto U.S. Pat. No. 2004/0243274 A1 Automatically Generating Embroidery Goldman Designs from a scanned image U.S. Pat. No. 2005/0182508 A1 Image Editing Device and Print/Embroidery Nimi et al Data Creating Device U.S. Pat. No. 2005/0234585 A1 Embroidery Data Producing Device, Muto et al embroidery data producing method, embroidery data producing control program stored on computer readable medium and embroidering method. 0006/0027152 A1 Sewing Machine Capable of Embroidery Lida et al 6,980,877 B1 Embroidery System Hagino et al. U.S. Pat. No. 2005/0060058 A1 Embroidery network Control System Cameron et al. U.S. Pat. No. 2005/0234584 A1 Apparatus and Program Stored on a Mizuno et al Computer-readable Medium for Producing Embroidery Data U.S. Pat. No. 2005/0289018 A1 On-line Personalized Apparel Design and Sullivan et al Sales Technology with Associated Manual and Fulfillment Techniques and Processes U.S. Pat. No. 2006/0027153 A1 Pattern Data Producing Device for Sewing Hirata et al Machine and Pattern Data Producing Control Program U.S. Pat. No. 2005/0120933 A1 Method of Providing an Adorned Article and Kronenberger an Adorned Article Made using the Method U.S. Pat. No. 2005/0211768 A1 Interactive Vending Systems Requiring Stillman Product Customization, Multimedia, Education, and Entertainment with Business Opportunities Modes and Methods U.S. Pat. No. 2006/0021270 A1 Method Private Labeling a Garment Hardy

One industry that has lagged behind in the use of embroidery and in particular in the use of logos is the furniture industry. While there is compelling evidence that consumers would appreciate an ability to have furniture adorned with desired logos, marks, trademarks, trade dress, symbols, etc., the current business models make fulfilling such very difficult and expensive. For example, furniture is generally large, bulky, expensive, and difficult to refurbish when compared to other products such as clothing. Therefore, while a clothing reseller may be able to spare the cost of lingering merchandise, a furniture reseller may not. Further, while a customer may be able to have clothing adorned after purchase, it may be prohibitively expensive to do so for furniture. Accordingly, there exists an unfulfilled need for custom embroidered furniture.

While the above references provide ways to produce embroidered and/or marked products, they fail to address the problems inherent in the furniture industry. Further, they fail to properly address the needs of owners of trademarks such that customers may truly have customized and marked products manufactured for them. In particular, some owners of marks are, often rightly, very particular about how their marks are used. In the current state of the art, there is no method of controlling how a mark would be used when provided for use with custom furniture.

What is needed is a system and/or method that solves one or more of the problems described herein and/or one or more problems that may come to the attention of one skilled in the art upon becoming familiar with this specification.

SUMMARY OF THE INVENTION

The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available systems and/or processes. Accordingly, the present invention has been developed to provide an system and/or process for manufacturing embroidered furniture.

In one embodiment, there is a system for manufacturing embroidered furniture. The system may include: a network configured to provide communication throughout the system; a furniture database module coupled to the network and configured to provide furniture data including flattened surface data for an article of furniture; a logo database module coupled to the network and configured to provide logo data; a design module coupled to the network and configured to selectably receive and integrate logo data and furniture data, thereby forming embroidery data; an embroidery supplier module coupled to the network and configured to receive embroidery data for the purpose of creating an embroidered surface; and/or a furniture manufacturer module coupled to the network and configured to receive an embroidered surface for assembly.

The design module may be able to receive a logo image from a user. The design module may provide a 3-D view of a selected article of furniture and/or a selected logo as placed on the article of furniture. The logo database may include logos owned by third parties that may have been licensed. The design module may function according to licensing rules selected by third parties that own the logos. Licensing rules may restrict placement of a licensed logo on a location type selected from the group consisting of furniture type, furniture model, orientation, furniture component, and surface type.

In another embodiment, there may be a method for manufacturing embroidered furniture. The method may include one or more of the following steps: providing a furniture database module; providing a logo database module; providing a design module configured to enable a user to select an article of furniture from the furniture database module and a logo from the logo database module and to virtually position the selected logo on the selected article of furniture; and/or converting the virtually positioned selected logo and selected article of furniture into embroidery data.

The method may further include receiving a logo image from a user. The design module may provide a perspective view of the selected logo and/or the selected article of furniture. The furniture database module may include a flattened model of an article of furniture. The logo database module may include a logo licensed by a third party. The logo database may include licensing rules to be applied during the method.

Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.

Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention can be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention.

These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order for the advantages of the invention to be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

FIG. 1 illustrates a block diagram of a system for manufacturing embroidered furniture according to one embodiment of the invention;

FIG. 2 illustrates, from a customer perspective, a method for manufacturing embroidered furniture according to one embodiment of the invention;

FIG. 3 illustrates, from a perspective of a service provider, a method of manufacturing embroidered furniture according to one embodiment of the invention;

FIG. 4 illustrates a customer display according to one embodiment of the invention; and

FIG. 5 illustrates a flat display of an exterior of an article of furniture according to one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “one embodiment,” “an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, different embodiments, or component parts of the same or different illustrated invention. Additionally, reference to the wording “an embodiment,” or the like, for two or more features, elements, etc. does not mean that the features are related, dissimilar, the same, etc. The use of the term “an embodiment,” or similar wording; is merely a convenient phrase to indicate optional features, which may or may not be part of the invention as claimed.

Each statement of an embodiment is to be considered independent of any other statement of an embodiment despite any use of similar or identical language characterizing each embodiment. Therefore, where one embodiment is identified as “another embodiment,” the identified embodiment is independent of any other embodiments characterized by the language “another embodiment.” The independent embodiments are considered to be able to be combined in whole or in part one with another as the claims and/or art may direct, either directly or indirectly, implicitly or explicitly.

Finally, the fact that the wording “an embodiment,” or the like, does not appear at the beginning of every sentence in the specification, such as is the practice of some practitioners, is merely a convenience for the reader's clarity. However, it is the intention of this application to incorporate by reference the phrasing “an embodiment,” and the like, at the beginning of every sentence herein where logically possible and appropriate.

Many of the functional units described in this specification have been labeled as modules, in order to more particularly emphasize their implementation independence. For example, a module may be implemented as a hardware circuit comprising custom VLSI circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components: A module may also be implemented in programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices or the like.

Modules may also be implemented in software for execution by various types of processors. An identified module of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the module and achieve the stated purpose for the module.

Indeed, a module of executable code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices. Similarly, operational data may be identified and illustrated herein within modules, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, merely as electronic signals on a system or network.

As used herein, the terms “logo,” “mark,” trademark,” etc. refer to graphics including but not limited to symbols, letters, designs, colors, shapes, etc. that may be owned in whole or in part by an entity.

FIG. 1 illustrates a block diagram of a system 100 for manufacturing embroidered furniture according to one embodiment of the invention. In the illustrated embodiment, there is a network 110 configured to provide communication throughout the system 100; a furniture database module 140 coupled to the network 110 and configured to provide furniture data including flattened surface data (See FIG. 5) for an article of furniture (See FIG. 4); a logo database module 150 coupled to the network 110 and configured to provide logo data; a design module 130 coupled to the network 110 and configured to selectably receive and integrate logo data and furniture data, thereby forming embroidery data (digitizing format); an embroidery supplier module 160 coupled to the network 110 and configured to receive embroidery data for the purpose of creating an embroidered surface; and a furniture manufacturer module 170 coupled to the network 110 and configured to receive an embroidered surface for assembly.

The network 110 may be any communication network that enables transfer of information between modules. Exemplary networks include the internet and/or a office intranet. In one embodiment, there may be a combination, such as wherein one or more modules may interact through the internet and one or more modules may interact through an intranet and/or over other means such as telephone and/or wireless networks.

The logo database module 150 may include one or more logos owned by third parties that may have been licensed. A logo may be stored as one or more image files, such as but not limited to pdf, jpg, bmp, and tiff files. In one embodiment, a logo is further converted and/or stored as a embroidery image file, such as those used by the embroidery design software called Maestro and sold by Hirsch International Corp. 200 Wireless Blvd. Hauppauge, N.Y. 11788.

The furniture database module 140 may include one or more image and/or CAD type files for each article of furniture. There may be a selection image that may be a photograph of an example of the article of furniture. Furniture may include but is not limited to chairs, couches, tables, accessories, wall art, sleeping bags, footlockers, etc. There may be a 3-D CAD type image that may be used by the design module 130 during the design process. There may be component data and/or imagery, or unfolded surface data, such as an unfolded view of one or more exterior surfaces of the article of furniture. In the simplest example, there may be a table including a top surface that may be embroidered. Accordingly, an “unfolded view” may include a single shape representing the top surface and measurements of the portion of fabric to be coupled to the top of the table when the furniture is assembled. A more complex version of this is illustrated in FIGS. 4 and 5.

The design module 130 may be able to receive a logo image from a user. The design module 130 may provide a 3-D view of a selected article of furniture and/or a selected logo as placed on the article of furniture. The design module 130 may function according to licensing rules selected by third parties that own the logos (according to location, size, color, number, mixing of marks, etc.). Licensing rules may restrict placement of a licensed logo on a location type selected from the group consisting of furniture type, furniture model, orientation, furniture component, and surface type. In one example, an owner of a mark may require that the mark only be placed on one or more specified substrates. In another example, an owner of a mark may require that only a single mark be placed on an article of furniture. In one example, licensing rules are enforced by programmed rule sets in the design module and/or by human overview. In another example, the design module 130 includes a “buffet” of licensing rules from which a third party owner of a mark may select in relation to licensing the mark. It is understood that one skilled in the art of programming could implement a rule-set in a plethora of ways.

The embroidery supplier module 160. In one embodiment, an embroidery supplier module 160 includes an embroidery machine produced by Tajima Embroidery Machines Ltd. Of 17/F., Tower 2, Enterprise Square, 9 Sheung Yuet Road, Kowloon Bay, Hong Kong, wherein such embroidery machine may use information from the design module 130, that may include but not is not limited to an embroidery image file linked by position and orientation data to unfolded surface data for a portion of an article of furniture. Accordingly, an embroidery supplier may be enabled with such data to produce embroidery on an appropriate substrate for later assembly to the article of furniture.

The furniture manufacturer module 170 may receive information from the design module 130 relating to selections made during the design process, such as but not limited to choice of an article of furniture, logo choice, logo location, logo orientation, and/or surface material (fabric, leather, design, etc.). The furniture manufacturer module 170 may include an assembly facility for assembly of furniture. The furniture manufacture module 170 may receive embroidery on an appropriate substrate for assembly. After assembly and inspection, the customized embroidered furniture may be delivered to the customer 120.

FIGS. 2 and 4 illustrate, from a customer perspective, a method 200 for manufacturing embroidered furniture according to one embodiment of the invention. In the illustrated embodiment, a customer 120 may access a design module 130 that may provide a display 400 as shown in FIG. 4. The customer 120 may select 210 an article of furniture from the furniture database module 140 by a menu choice 412. The customer 120 may select a logo 220 and/or upload a logo 220 by selecting menu choices 414 and/or 416 respectively. An uploaded logo may be converted to an embroidery image file after being uploaded. The customer 120 may though a GUI (graphical user interface) move 240 and/or alter representations of the article of furniture and/or logo until a final desired design is achieved (418 menu button, 424 position and orientation changes, 430 mouse pointer, and logo(s) 428 on FIG. 4). In one example, logo size may be altered. In another example, logo color may be altered. In a further example, a plurality of logos may be included in a design.

A design may be reviewed 422, such as by validating a design according to a rule-set and/or approval by a human design editor. Upon completion of a design, a customer 120 may choose to order the custom ensemble 250. Once the design has been implemented by a system, the customer receives 260 the custom embroidered furniture.

FIG. 3 illustrates, from a perspective of a service provider, a method of manufacturing embroidered furniture according to one embodiment of the invention. In the illustrated embodiment, there is a method 300 for manufacturing embroidered furniture. The illustrated method 300 includes: providing a furniture database module 310; providing a logo database module 320; providing an ability 330 to receive and convert a graphic image to an embroidery file; providing a design module 340 configured to enable a user to select an article of furniture from the furniture database module and a logo from the logo database module and to virtually position the selected logo on the selected article of furniture; generating orders 350 for embroidery and furniture assembly by converting the virtually positioned selected logo and selected article of furniture into embroidery data and assembly data.

The method may further include receiving a logo image from a user. The design module may provide a perspective view of the selected logo and/or the selected article of furniture. The furniture database module may include a flattened model of an article of furniture such as but not limited to as shown in FIG. 5. The logo database module may include a logo licensed by a third party. The logo database may include licensing rules to be applied during the method.

FIG. 5 illustrates a flat display of an exterior of an article of furniture according to one embodiment of the invention. In particular, portions displayed in FIG. 5 relate to the virtual image of an article of furniture of FIG. 4. Relations are as follows: 560 relates to 440, 570 relates to 442, 580 relates to 444, 520 relates to 434, 530 relates to 436, 540 relates to 438, and 510 relates to 432. Accordingly, wherein a customer 120 and/or designer may place a logo on a portion of the virtual furniture 426 of FIG. 4, an appropriately shaped surface portion may be embroidered and delivered for assembly.

It is understood that the above-described embodiments are only illustrative of the application of the principles of the present invention. The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiment is to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claim rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

For example, although the Figures show steps performed in a particular order, it is understood that the steps may be performed in any reasonable order.

As a further example, while a particular partitioning of surface portions is disclosed in FIG. 5, it is understood that the ways of partitioning surface portions of furniture are plethoric and are best adapted to the particular practices and needs of a furniture assembly module.

Thus, while the present invention has been fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment of the invention, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made, without departing from the principles and concepts of the invention as set forth in the claims. 

1. A system for manufacturing embroidered furniture, comprising: a network configured to provide communication throughout the system; a furniture database module coupled to the network and configured to provide furniture data including flattened surface data for an article of furniture; a logo database module coupled to the network and configured to provide logo data; a design module coupled to the network and configured to selectably receive and integrate the logo data and the flattened furniture data, thereby forming embroidery data; an embroidery supplier module coupled to the network and configured to receive embroidery data for the purpose of creating an embroidered surface; and a furniture manufacturer module coupled to the network and configured to receive an embroidered surface for assembly.
 2. The system of claim 1, wherein the design module comprises a receiving module configured to receive a logo image from a user.
 3. The system of claim 1, wherein the design module provides a 3-D view of the article of furniture and a selected logo as placed on the article of furniture.
 4. The system of claim 1, wherein logo database module includes a licensed logo of a third party.
 5. The system of claim 4, wherein design module functions according to a licensing rule selected by the third party.
 6. The system of claim 5, wherein the licensing rule restricts placement of the licensed logo on a location type selected from the group consisting of furniture type, furniture model, orientation, furniture component, and surface type.
 7. A method for manufacturing embroidered furniture, comprising the steps of: providing a furniture database module; providing a logo database module; providing a design module configured to enable a user to select an article of furniture from the furniture database module and a logo from the logo database module and to virtually position the selected logo on the selected article of furniture; and converting the virtually positioned selected logo and selected article of furniture into embroidery data.
 8. The method of claim 7, further comprising receiving a logo image from a user.
 9. The method of claim 7, wherein the design module provides a perspective view of the selected logo and the selected article of furniture.
 10. The method of claim 7, wherein the furniture database module includes a flattened model of an article of furniture.
 11. The method of claim 7, wherein the logo database module includes a logo licensed by a third party.
 12. The method of claim 11, wherein the logo database module includes licensing rules to be applied during the method.
 13. A system for manufacturing embroidered furniture, comprising: a network configured to provide communication throughout the system; a furniture database module coupled to the network and configured to provide furniture data; a logo database module coupled to the network and configured to provide logo data; and a design module coupled to the network and configured to selectably receive and integrate logo data and furniture data, thereby forming embroidery data.
 14. The system of claim 13, wherein the design module comprises being able to receive a logo image from a user.
 15. The system of claim 13, wherein the design module provides a 3-D view of a selected article of furniture and a selected logo as placed on the article of furniture.
 16. The system of claim 13, wherein logo database includes logos owned by third parties that have been licensed.
 17. The system of claim 16, wherein design module functions according to licensing rules selected by third parties that own the logos.
 18. The system of claim 17, wherein the licensing rules restrict placement of a licensed logo on a location type selected from the group consisting of furniture type, furniture model, orientation, furniture component, and surface type.
 19. The system of claim 13, further comprising an embroidery supplier module coupled to the network and configured to receive embroidery data for the purpose of creating an embroidered surface.
 20. The system of claim 19, further comprising a furniture manufacturer module coupled to the network and configured to receive an embroidered surface for assembly. 